Force protector for pallet rack systems

ABSTRACT

A force absorbing column protector device is disclosed. The force absorbing column protector has a plurality of surfaces adjacent a structure to be protected from an external force encountering the structure. At least one of the surfaces has spring assemblies positioned intermediate one surface and the structure. Two of the surfaces are arranged sloping from opposite ends of the structure. It is the combination of the sloping surfaces and the spring assemblies that provide a measure of protection to a column. Some or all of the spring assemblies may be of a color that indicates a characteristic of the force absorbing column protector device.

FIELD OF THE INVENTION

The present invention relates generally to warehouse storage arrangements and systems for pallet racks of multiple heights and depths accessible by forklift trucks and, more particularly, to a protector for such pallet racks from the force of an impact by the forklift trucks.

BACKGROUND OF THE INVENTION

Advances in warehouse storage systems in today's markets continue to be made. These advances range from a simple back room where boxes of supplies were stacked to today's huge warehouses with multiple sections of racks extending across an allotted space in a warehouse to support pallets two and three deep.

A section in a pallet rack storage system includes vertical columns to support rails on which carts carry pallets that can be retrieved, one by one, from an aisle by a forklift. The “push-back” cart storage systems are well known in the art and have upright members that are subject to being damaged by forklifts.

While some damage to these systems is caused by careless operators, the majority of damage occurs from careful operators occasionally encountering these upright members. When a file system is damaged, there may be costly delays in obtaining access to whatever was stored. In order to address these costly delays, force absorbing arrangements have been proposed.

Related art that addresses the above problems includes the following patents.

U.S. Pat. No. 4,113,110, issued to Mittag on Sep. 12, 1978, discloses a storage rack is provided with posts and shelving for supporting goods. The posts are of the type having keyhole slots. Several types of post protectors are disclosed. Both of the post protectors have fasteners engageable with the keyhole slots to provide means to secure them to a storage rack to minimize damage to the storage rack posts in the event that the posts are accidentally struck by various types of vehicles such as fork lift trucks and the like. The one post protector is provided for mounting on the front face of the post and extends vertically a number of feet to protect the storage rack post from ground level upwards to a desired point. A second corner post protector is provided for mounting at right angles to the other first described post protector and provides means to shield the post from blows which might be directed or received at generally right angles to those receivable against the other first described post protector.

U.S. Pat. No. 4,239,122, issued to Klein on Dec. 16, 1980, discloses a reinforced storage rack for substantially resisting forklift impact, bending and deflection. The reinforced rack has a plurality of composite post assemblies each including a metal post and an impact-resistant wooden core. Desirably, the reinforced rack also has a plurality of generally horizontal composite beam assemblies each of which include a metal beam and a deflection-resistant wooden core.

U.S. Pat. No. 5,369,925, issued to Vargo on Dec. 6, 1994, discloses a post protector which is placed around a portion of a column to be protected from impact or shock loading. The post protector is fastened to the floor and non-destructively absorbs impacts from objects which would otherwise impact the column. The post protector comprises an elongated portion which is placed adjacent and around the column. A flange is also provided which extends from the elongated portion and is fastened to the floor via openings through the flange. Fasteners are inserted through the openings which anchor the post protector to the floor. The flange also includes an elastic membrane which allows the post protector to elastically move upon impact whereby the post protector non-destructively absorbs the impact force of an object.

U.S. Pat. No. 6,609,620 B1, issued to Kautz et al. on Aug. 26, 2003, discloses a storage rack column protector designed to protect a column from damage from a straddle or outrigger type fork truck. If one of the outrigger forks is aimed at and headed toward the protected column, a ramp on the protector raises the offending outrigger fork and thus also the wheel of the fork truck. Should the fork truck continue advancing, a stop will bring the outrigger fork and the fork truck to a complete stop before it makes impact with the column.

U.S. Published Patent Application No. 2004/0094496 A1, issued to Kautz et al. on Aug. 26, 2003, discloses an integral pallet rack post reinforcement kit for protecting the lower pallet rack frame from forklifts, etc. which takes the place of the lower six to twelve inches of the front frame post and fastened in its place. The kit is, for example, square tube welded to a three-sided outer clamp which bears a front angle deflector. These components are welded to a four inch by twelve inch by three-eighths inch footplate with two three-quarter inch by five inch by half inch wedge bolt anchors for attachment to the warehouse floor. Accordingly, this footplate replaces the original footplate. By using the reinforcement kit with the angle deflector, frontal impacts are deflected off to one side. The front post of the original pallet rack the present reinforcement kit would, over time, fail from cyclical or repeated impacts.

While these patents and other previous methods have attempted to solve the problems that they addressed, none have utilized or disclosed a V-shaped force absorbing column protector with color coded spring assemblies and elongated connecting holes, as does embodiments of the present invention.

Therefore, a need exists for a force protector for pallet rack systems with these attributes and functionalities. The force protector for pallet rack systems according to embodiments of the invention substantially departs from the conventional concepts and designs of the prior art. It can be appreciated that there exists a continuing need for a new and improved force protector for pallet rack systems which can be used commercially. In this regard, the present invention substantially fulfills these objectives.

The foregoing patent and other information reflect the state of the art of which the inventors are aware and are tendered with a view toward discharging the inventor's acknowledged duty of candor in disclosing information that may be pertinent to the patentability of the present invention. It is respectfully stipulated, however, that the foregoing patent and other information do not teach or render obvious, singly or when considered in combination, the inventor's claimed invention.

BRIEF SUMMARY OF THE INVENTION

The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a force absorbing column protector.

Generally speaking, the present invention provides a device for attaching to the upright legs of storage racks that are usually accessed by forklift trucks to prevent damage to the racks when encountered by a forklift truck.

Briefly, a device that is constructed and arranged according to the present invention includes at least two surfaces to fit adjacent an upright part of a structure to be protected from an external force encountering the structure. The device includes a fixed surface located a distance from the upright leg and includes springs supported intermediate the structure and the surfaces. An external force that is directed at the upright part is at least partially intercepted by the surfaces and at least partially absorbed by the springs.

One aspect of the present invention is that it absorbs the force of impact from a fork lift.

Another aspect of the present invention is that it facilitates the extension of useful life of cart storage system columns.

Another aspect of the present invention is that is helps to prevent damage to concrete flooring associated with cart storage system columns.

Another aspect of the present invention is that no floor anchors are needed to connect the present invention to a cart storage system column.

Another aspect of the present invention is that it is easy to install on a structural or Rollform column.

Another aspect of the present invention is that it reduces down time due to column or rack repair.

Another aspect of the present invention is that it may be made from readily available materials.

Another aspect of the present invention is that it may be made economically.

These and other features and advantages of the present invention will be presented in more detail in the following specification of the invention and the accompanying figures, which illustrate by way of example the principles of the invention.

There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a rear perspective view of a force protector for pallet rack systems, according to an embodiment of the present invention.

FIG. 2 illustrates a right side perspective view of a force protector for pallet rack systems, according to an embodiment of the present invention.

FIG. 3 illustrates a right side perspective view of a force protector for pallet rack systems installed on a representative leg of a storage rack, according to an embodiment of the present invention.

FIG. 4 illustrates a top plan view of a force protector for pallet rack systems, according to an embodiment of the present invention.

FIG. 5 illustrates a rear plan view of a force protector for pallet rack systems, according to an embodiment of the present invention.

FIG. 6 is an illustration of how a force protector for pallet rack systems is located on a leg of a storage rack, according to an embodiment of the present invention.

FIG. 7 is an illustration of a multi-level storage rack as an aid in describing one use of an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described in detail with reference to a few preferred embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known operations have not been described in detail so not to unnecessarily obscure the present invention.

Referring now to FIG. 1 through FIG. 7 a force protector for pallet rack systems device 10 is comprised of an outer surface 11, formed in a generally “V” shape, as indicated at sloping surfaces 12 and 13, with opposite sides 14 and 15 forming a space to fit around the structure to be protected. A plurality of resilient springs 16, with ends 17, are located to fit intermediate an upright portion of the structure to be protected and a panel 18, that is welded, as indicated by weld spots 19 and 20.

The panel 18 is fitted against a panel 25 approximately midway between the springs 16. The panel 18 and the panel 25 are welded at 21 and 22 to produce a maximum support for the springs 16. The ends 17 of the springs 16 fit against the upright portion of the structure to be protected through the use of fasteners 31.

The generally “V” configuration, or arrangement, or the outer surface 11 will deflect a blow from, for example, a forklift truck that would hit the pallet rack upright support leg. While the material from which the device is constructed may vary depending on the size of the force expected, to protect an upright support leg of a storage rack, 3/16 inch sheet metal that is 48 inches wide and 96 inches long has been found entirely satisfactory.

After the side panels are formed, elongated openings indicated by the reference numbers 23 and 24 are formed in the side panels 14 and 15 for attaching the device to the upright support leg in a desired location using fasteners 30. The configuration of these openings 23 and 24 provides a safety feature for the force protector for pallet rack systems device 10.

When the springs 16 are nearly compressed completely, having about 3/16 inch remaining, the elongated configuration of the elongated openings 23 and 24 permits an additional safety feature.

The springs 16 have a customary stiffness to create sufficient resilience to, at least partially, absorb such a force expected when the present invention is encountered by a forklift. In one embodiment each spring 16 is formed from 3/16 inch bar stock material. Springs 16 may have a color to indicate the level of stiffness, e.g. green for a light level of stiffness, yellow for a moderate level of stiffness, red for high level of stiffness, blue for maximum level of stiffness.

The sloping surfaces 12 and 13 will partially deflect such a force, and the springs 16 will absorb any remaining force. It is this combination of the springs 16 and the sloping surfaces 12 and 13 that provide a maximum protection.

In one embodiment of the present invention a force protector device for an upright leg of pallet rack systems is comprised of a generally V-shape structure forming a space to fit around the upright leg, a plurality of coplanar surfaces connected to the V-shaped structure, adjacent the upright leg and having a plurality of elongated holes through which fasteners may be used to connect the force protector device to an upright leg of a pallet rack system, at least one panel affixed inside the V-shape structure and connecting the coplanar surfaces, and at least one spring connected to the panel wherein the spring has an end portion facing the upright leg and connected to the spring with a fastener.

In another embodiment of the present invention a force protector device for an upright leg of pallet rack systems is comprised of a generally V-shape structure having an upper portion and a lower portion and forming a space to fit around the upright leg, two coplanar surfaces connected to the V-shaped structure, adjacent the upright leg and having four elongated holes, a first panel affixed inside the upper portion and connecting the coplanar surfaces, a second panel affixed inside the lower portion and connecting the coplanar surfaces, two upper spring assemblies connected to the first panel, and two lower spring assemblies connected to the second panel, wherein the two upper spring assemblies and the two lower spring assemblies are coated with a color indicating a characteristic of the force protector device. Also in this embodiment, each spring assembly is comprised of a spring formed from a 3/16 inch bar stock material and the V-shape structure and two coplanar surfaces are formed from 3/16 inch sheet metal.

In yet another embodiment a device to absorb a force directed at an upright part of a structure is comprised of a plurality of surfaces supported adjacent the upright part; a fixed surface located a predetermined distance from the upright part; and resilient means having a color supported intermediate the plurality of surfaces and the fixed surface to permit the plurality of surfaces movement relative to the upright part; whereby a force that is directed at the upright part is at least partially intercepted by the surfaces and at least partially absorbed by the resilient means. The embodiment is further defined to have two surfaces, one located on each side of the upright part; the resilient means includes at least two coil springs and the plurality of surfaces each includes opening for attaching the device to the upright part.

From the foregoing, it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. For example, many of the features and components described above in the context of a particular force protector for pallet rack systems device configuration can be incorporated into other configurations in accordance with other embodiments of the invention. Accordingly, the invention is not limited except by the appended claims. 

1. A force protector device for an upright leg of pallet rack systems comprising: a generally V-shape structure forming a space to fit around the upright leg, a plurality of coplanar surfaces connected to the V-shaped structure, adjacent the upright leg and having a plurality of holes, at least one panel affixed inside the V-shape structure and connecting the coplanar surfaces, and at least one spring connected to the panel wherein the spring has an end portion facing the upright leg and connected to the spring with a fastener.
 2. The force protector device of claim 1, wherein the plurality of holes consists of elongated holes.
 3. The force protector device of claim 2, further comprising a plurality of fasteners dimensioned to connect the force protector device to an upright leg using the elongated holes.
 4. A force protector device for an upright leg of pallet rack systems comprising: a generally V-shape structure having an upper portion and a lower portion and forming a space to fit around the upright leg, two coplanar surfaces connected to the V-shaped structure, adjacent the upright leg and having four elongated holes, a first panel affixed inside the upper portion and connecting the coplanar surfaces, a second panel affixed inside the lower portion and connecting the coplanar surfaces, two upper spring assemblies connected to the first panel, and two lower spring assemblies connected to the second panel, wherein the two upper spring assemblies and the two lower spring assemblies are coated with a color indicating a characteristic of the force protector device.
 5. The force protector device of claim 4, wherein each spring assembly is comprised of a spring formed from a 3/16 inch bar stock material and the V-shape structure and two coplanar surfaces are formed from 3/16 inch sheet metal.
 6. A device to absorb a force directed at an upright part of a structure, comprising: a plurality of surfaces supported adjacent said upright part; a fixed surface located a predetermined distance from said upright part; and resilient means having a color supported intermediate said plurality of surfaces and said fixed surface to permit said plurality of surfaces movement relative to said upright part; whereby a force that is directed at said upright part is at least partially intercepted by said surfaces and at least partially absorbed by said resilient means.
 7. The device to absorb a force directed at an upright part of a structure as described by claim 6 wherein said plurality of surfaces includes two, one located on each side of said upright part.
 8. The device to absorb a force directed at an upright part of a structure as described by claim 6 wherein said resilient means includes at least two coil springs.
 9. The device to absorb a force directed at an upright part of a structure as described by claim 6 wherein said plurality of surfaces each includes opening for attaching said device to said upright part. 